Dodge RAM TRUCK 1500 1995 Service Manual page 1333

21 - 5 0 NV4500 MANUAL TRANSMISSION —
BR
Fig. 5 Removing Shift Lever Extension With Toot
8783
(5) Raise and support vehicle.
(6) Mark propeller shaft and axle yokes for align­
ment reference. Use paint, scriber, or chalk to mark
yokes.
(7) Remove U-joint clamp strap screws and remove
clamps.
(8) Remove propeller shaft.
(9) Disconnect and remove exhaust system Y-pipe.
(10) Disconnect wires at speed sensor and backup
light switch.
(11) Support engine with adjustable safety stand
and wood block.
(12) If transmission is to be disassembled for re­
pair, remove drain bolt at bottom of PTO cover and
drain lubricant from transmission.
(13) Remove bolts/nuts attaching transmission to
rear mount.
(14) Support transmission with a transmission
jack. Secure transmission to jack with safety chains.
(15) Remove rear crossmember.
(16) Remove bolts attaching clutch slave cylinder
to clutch housing. Then move cylinder aside for work­
ing clearance.
(17) Remove transmission harness wires from clips
on transmission shift cover.
(18) Remove bolts attaching transmission to clutch
housing.
Abnormal wear and damage to internal compo­
nents Is frequently the end result of insufficient lu­
bricant, non-recommended lubricants, or Improper
operation.
SLIPS OUT QF GEAR
Transmission disengagement may be caused by
misaligned or damaged shift components, or worn
teeth on the mainshaft gears or synchro components.
Incorrect assembly will also contribute to gear disen­
gagement.
LOW LUBRICANT LEVEL
Insufficient transmission lubricant is usually the
result of leaks, or inaccurate fluid level check or refill
method.
Leaks will be evident by the presence of gear oil
around the leak point. If leakage is not evident, the
condition is probably the result of an underfill condi­
tion.
If air powered lubrication equipment is used to fill
a transmission, be sure the equipment is properly
calibrated. Equipment out of calibration can lead to
an underfill condition.
CLUTCH PROBLEMS
Worn, damaged, or misaligned clutch components
can cause difficult shifting, gear clash and noise.
A damaged pilot bearing will cause noise. If bear­
ing damage is severe, drive gear misalignment and
hard shifting can also occur.
A worn or damaged clutch disc, pressure plate, or
release bearing can cause hard shifting and gear
clash.
Damaged or worn clutch hydraulic components, or
leaks in the fluid lines or cylinders will cause hard
shifting and gear clash. Failure of one of the clutch
hydraulic cylinders can result in incomplete clutch
release or engagement.
Verify that clutch components are all in good con­
dition before removing the transmission for repair.
TRANSMISSION REMOVAL (2-WHEEL DRIVE)
(1) Disconnect battery negative cable.
(2) Shift transmission into Neutral.
(3) Remove screws attaching shift boot to floorpan.
Then slide boot upward on lever extension.
(4) Remove shift lever extension with Remover/In­
staller Tool 6783 as follows:
(a) Scribe mark position of extension on shank of
shift lever.
(b) Position notched, lower end of tool just under
square shank of shift lever (Fig. 5).
(c) Position tool upper jaws under flange on
shift lever extension (Fig. 5).
(d) Tighten tool screw to pull extension off
square shank of shift lever.
(e) Remove lever extension and tool.